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2013 AEP BRO Pulverizer Breakout Session. July 2013 By Michael Leadmon Ed Dillow. Emergencies – Call “HELP” (4357) on house phones, and the Conference center will initiate the response. - PowerPoint PPT Presentation
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2013 AEP BRO
2013 AEP BRO
Pulverizer Pulverizer
Breakout Breakout
SessionSession
July 2013July 2013
By Michael Leadmon
By Michael Leadmon
Ed DillowEd Dillow
Safe
ty B
rief
Safe
ty B
rief
Emergencies – Call “HELP”
Emergencies – Call “HELP”
(4357) on house phones,
(4357) on house phones,
and the Conference center
and the Conference center
will initiate the response.
will initiate the response.
Fire Alarms will sound if
Fire Alarms will sound if
there is a fire. Instructions
there is a fire. Instructions
will be announced over the
will be announced over the
PA system. Follow the
PA system. Follow the
evacuation instructions.
evacuation instructions.
Severe weather, Power
Severe weather, Power
outages, or other
outages, or other “situations” will be
“situations” will be evaluated and taken care of
evaluated and taken care of
by the Convention Center,
by the Convention Center,
again announcements will
again announcements will
be made as required.
be made as required.
Changin
g
Changin
g
tim
es
!ti
mes
!
2011 - 2011 - Pulverizer
Pulverizer Curtailments $10,300,000
Curtailments $10,300,000
total with 92% at units
total with 92% at units
without spare mills. 4th
without spare mills. 4th
Leading contributor of
Leading contributor of
Equivalent forced outage rate
Equivalent forced outage rate
among the 5 – 800 series
among the 5 – 800 series
units. Focus : additional
units. Focus : additional
throughput to eliminate
throughput to eliminate
curtailments, improve
curtailments, improve
reliability and capture the
reliability and capture the
“money left on the table”.
“money left on the table”.
2012 – 2012 – No industrial load,
No industrial load,
curtailments covered with
curtailments covered with
“excess power”, gas plants
“excess power”, gas plants
running and taking coal load,
running and taking coal load,
not much justification for
not much justification for
spending money for pulverizer
spending money for pulverizer
load curtailments!
load curtailments! 2013 –
2013 – Coal and Gas battle
Coal and Gas battle
for market,, pure economics !!
for market,, pure economics !!
Throughput again becomes an
Throughput again becomes an
issue! Capture the $
issue! Capture the $
whenever available.
whenever available.
Why
focu
s on
Why
focu
s on
Pulv
eri
zers
?
Pulv
eri
zers
?
90%
5% 4%1%
Coal Maintenance Chemicals Other
Pulv
eri
zers
mean
Pulv
eri
zers
mean
Fuel D
eliv
ery
Fuel D
eliv
ery
Flexibility – Boilers were designed
Flexibility – Boilers were designed
considering the location of the mine,
considering the location of the mine,
and will probably not be burning the
and will probably not be burning the
coal today it was designed to burn 3-5
coal today it was designed to burn 3-5
decades ago!
decades ago! Dispatch cost - Real, and we are
Dispatch cost - Real, and we are
starting to educate our employees
starting to educate our employees
about this. Survival of the fittest! Small
about this. Survival of the fittest! Small
incremental improvements, do not
incremental improvements, do not
expect single events to make a
expect single events to make a
tremendous impact!
tremendous impact! Idea generation – Employee
Idea generation – Employee
involvement will create lots of ideas on
involvement will create lots of ideas on
how to improve ! Do not overlook this
how to improve ! Do not overlook this
valuable resource.
valuable resource. Reality Check - Make sure you are not
Reality Check - Make sure you are not
asking your equipment to do more that
asking your equipment to do more that
it is capable of doing! Original design
it is capable of doing! Original design
basis did not include any “frills”!
basis did not include any “frills”!
Changin
g
Changin
g
Opera
ting
Opera
ting
Condit
ions
Condit
ions
Low Loads at night – Pushing
Low Loads at night – Pushing
established limits to keep
established limits to keep
from loosing money during
from loosing money during
off peak hours.
off peak hours. Safety Point
Safety Point : :
Make provisions to ensure
Make provisions to ensure
the coal conduit minimum
the coal conduit minimum
velocities are maintained
velocities are maintained
(3000ft/min)
(3000ft/min)Ash content – higher ash,
Ash content – higher ash,
less energy, more volume,
less energy, more volume,
greater slagging potential.
greater slagging potential.
Moisture – more heat input
Moisture – more heat input
needed to drive off the
needed to drive off the
moisture. Air heaters ! More
moisture. Air heaters ! More
equipment will be involved ,
equipment will be involved ,
look more at systems !
look more at systems !
Dispatch Dispatch Cost of Cost of $36.00$36.00
Figure used Figure used to calculate to calculate
the $9.5M the $9.5M curtailmentscurtailments
Fuel Cost & Handling
Fuel Cost & Handling
($/MWh) $ 32.40
($/MWh) $ 32.40 Maintenance
Maintenance
($/MWh) $ 1.95
($/MWh) $ 1.95 Major Chemicals
Major Chemicals
($/MWh) $ 1.58
($/MWh) $ 1.58 Other
Other
($/MWh) $ 0.07
($/MWh) $ 0.07The target is obvious!
The target is obvious!
How
do w
e c
ut
How
do w
e c
ut
dis
patc
h
dis
patc
h
cost
s???
co
sts?
??
Fuel cost represents 90%
Fuel cost represents 90%
of the dispatch cost so it
of the dispatch cost so it
is the most likely place
is the most likely place
to find improvement.
to find improvement. To drop the dispatch cost
To drop the dispatch cost
$1.00, it takes about a
$1.00, it takes about a
$2.00 cost per ton
$2.00 cost per ton reduction for delivered
reduction for delivered
coal (average, you
coal (average, you actual cost may change)
actual cost may change)
$20.00 price variation
$20.00 price variation
for our 12,000 Btu/# AEP
for our 12,000 Btu/# AEP
coal is across the
coal is across the eastern fleet . So
eastern fleet . So improvements are
improvements are possible!possible!
Dro
ppin
g c
oal
Dro
ppin
g c
oal
pri
ces!
pri
ces!
Caution, each unit was
Caution, each unit was
originally designed to run on
originally designed to run on
a specific coal
a specific coal A drop in coal price usually
A drop in coal price usually
means increased ash, lower
means increased ash, lower
heating value, or some other
heating value, or some other
undesirable characteristic.
undesirable characteristic.
Example, given a heat rate
Example, given a heat rate
of 10,000 BTU/KWhr and a
of 10,000 BTU/KWhr and a
coal heating value of
coal heating value of
12,000BTU/#, saving $2/ton
12,000BTU/#, saving $2/ton
for the same coal reduces
for the same coal reduces
the dispatch cost about
the dispatch cost about
$1.00! Saving that
$1.00! Saving that same$2/ton and loosing 500
same$2/ton and loosing 500
BTU/# raises your dispatch
BTU/# raises your dispatch
cost by the same $1.00!
cost by the same $1.00!
Realit
y :
You g
et
Realit
y :
You g
et
what
you g
et
!
what
you g
et
!
Rarely do we get the coal
Rarely do we get the coal
the units are design for!
the units are design for!
It is up to the pulverizer
It is up to the pulverizer
owners and operators to
owners and operators to
get the load from the
get the load from the
pulverizers. Know your
pulverizers. Know your
mills, and the modifications
mills, and the modifications
required to get them to
required to get them to
where you want to be!
where you want to be!
Wholesale replacements
Wholesale replacements
are not always necessary.
are not always necessary.
Our speakers today are
Our speakers today are
here to help by providing
here to help by providing
options for coal condition
options for coal condition
flexibility and throughput
flexibility and throughput
increases! increases!
Prese
nta
tions
Prese
nta
tions
B&W – Our alliance partner will discuss
B&W – Our alliance partner will discuss
upgrades that have made overseas, the
upgrades that have made overseas, the
real data showing improvements in
real data showing improvements in
performance, and the importance of
performance, and the importance of
knowing what you want and expect to
knowing what you want and expect to
achieve with your modifications!
achieve with your modifications!
Alstom – Rotating classifier vs. modified
Alstom – Rotating classifier vs. modified
stationary classifier accompanied by
stationary classifier accompanied by
throat mods and wide tires. Buy only the
throat mods and wide tires. Buy only the
upgrades that you need.
upgrades that you need.
Smartburn – Explores modeling of the
Smartburn – Explores modeling of the
MPS89 and pre-mod analysis.
MPS89 and pre-mod analysis.
Illinois Basis Coal – Possible solution to
Illinois Basis Coal – Possible solution to
economic problems? Pat Malone will
economic problems? Pat Malone will
discuss AEP test burns.
discuss AEP test burns.
Stock Equipment – Will discuss feeder
Stock Equipment – Will discuss feeder
design criteria to meet NFPC
design criteria to meet NFPC
requirements and how our old equipment
requirements and how our old equipment
may be pushing those limits. Inspection
may be pushing those limits. Inspection
guidelines, repair procedures and
guidelines, repair procedures and
preventative action suggestions!
preventative action suggestions!
AEP Big Sandy - Real data and
AEP Big Sandy - Real data and
experiences from AEP’s first rotating
experiences from AEP’s first rotating
classifier installation!
classifier installation!
Thank
You
Thank
You
! !